1986 Kawasaki Vulcan 750 Repair Manual

The 1986 Kawasaki Vulcan 750 is a V-twin cruiser motorcycle featuring liquid cooling, shaft drive, and dual carburetors. This repair manual covers comprehensive maintenance, troubleshooting, and repair procedures for engine, transmission, electrical systems, brakes, suspension, and chassis components. Below are key sections for specifications, maintenance schedules, engine repair, transmission service, electrical systems, brakes, suspension, and troubleshooting.

Specifications

Technical specifications for the 1986 Kawasaki Vulcan 750 including engine, transmission, chassis, and electrical details.

Maintenance Schedule

Regular maintenance intervals for optimal performance and longevity.

1. Oil change: Every 3,000 miles or 6 months
2. Oil filter replacement: Every other oil change
3. Spark plugs: Replace every 7,500 miles
4. Air filter: Clean every 3,000 miles, replace every 12,000 miles
5. Valve clearance: Check every 6,000 miles
6. Brake fluid: Replace every 2 years
7. Coolant: Replace every 2 years or 24,000 miles

WARNING! Always use genuine Kawasaki parts for replacement. Follow torque specifications precisely.

Engine Repair

Comprehensive engine service procedures including top-end and bottom-end repairs.

1. Cylinder head removal: Drain coolant, remove camshafts, unbolt head
2. Valve adjustment: Set clearance to 0.10-0.15mm (intake), 0.15-0.20mm (exhaust)
3. Piston replacement: Remove cylinders, inspect rings, replace as needed
4. Crankshaft service: Check runout, replace bearings if worn
5. Camshaft timing: Align timing marks precisely during reassembly

CAUTION! Engine components are precision parts; handle with care and use proper tools.

Transmission Service

• Gear inspection: Check for worn dogs and engagement surfaces
• Shift mechanism: Inspect shift forks and drum for wear
• Clutch replacement: Replace friction plates and springs as set
• Shaft drive service: Check universal joint and final drive gear lash
• Transmission oil: Use SAE 80W-90 gear oil, change every 12,000 miles

Electrical Systems

Diagnosis and repair of charging, ignition, and lighting systems.

Charging system: Stator output 14.2-15.2V at 5000 RPM, regulator/rectifier test procedures

Ignition system: CDI unit testing, pickup coil resistance 90-120 ohms, spark advance operation

Lighting: Headlight adjustment, turn signal replacement, brake light switch adjustment

Battery: 12V 14Ah, specific gravity 1.280, maintain proper electrolyte level

Brake Systems

Front disc brake and rear drum brake service procedures.

1. Front brake pads: Replace when worn to 1mm thickness
2. Brake fluid: Use DOT 4, bleed system annually
3. Brake discs: Check for warpage (max 0.15mm runout)
4. Rear brake shoes: Replace when lining worn to 1mm
5. Brake adjustment: Proper free play in rear brake pedal

Tip: Always clean brake components with brake cleaner only.

Suspension & Chassis

Front fork and rear shock service, steering head bearing adjustment.

1. Front fork oil: Replace every 15,000 miles, use 10W fork oil
2. Fork seals: Replace if leaking, use proper seal driver
3. Steering head bearings: Adjust for minimal play without binding
4. Rear shocks: Adjust preload for riding conditions and load
5. Wheel bearings: Check for play, repack with grease annually
6. Frame inspection: Check for cracks at stress points

WARNING! Proper suspension setup is critical for handling and safety.

Carburetor Adjustment

Dual Mikuni CV carburetor synchronization and jetting procedures.

Cooling System

Radiator, water pump, and thermostat service and maintenance.

CAUTION! Never open radiator cap when engine is hot. Use proper coolant mixture.

Safety Precautions

Always use proper safety equipment including eye protection, gloves, and shop safety standards. Follow torque specifications using calibrated torque wrenches. Keep work area clean and organized.

Troubleshooting

Technical Support: Contact Kawasaki dealership for factory technical assistance

Parts: Use genuine Kawasaki parts for optimal performance and reliability